Heterophasic polypropylene resin with long chain branching

ABSTRACT

Heterophasic polypropylene resin having a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min, determined according to ISO 1133, comprising a propylene random copolymer matrix phase (A), and an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase, wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) being present in the resin in an amount of 15 to 45 wt % whereby the XCS fraction has an ethylene content of 25 wt % or lower, and a fraction insoluble in p-xylene at 25° C. (XCU fraction), said heterophasic polypropylene resin being characterized by a strain hardening factor (SHF) of 1.7 to 4.0 when measured at a strain rate of 3.0 s −1  and a Hencky strain of 3.0.

The present invention relates to a heterophasic polypropylene resin comprising a propylene random copolymer matrix phase and an ethylene-propylene copolymer rubber phase dispersed within the matrix phase showing a homogeneous branching structure. Further, it relates to a process for producing such a polypropylene resin and the use of such a resin for the production of an article. The present invention also relates to the replacement of polyethylene by polypropylene.

Today, polyethylene is used in countless applications such as cables, film, pipes, and the like. Relatively easy processing allows large production scales such as for example necessary when producing insulation and semiconductive layers for power cables. The use of polyethylene nevertheless finds its limitations when the final products shall withstand temperatures of more than 90° C. Polypropylene allows much higher temperature stability. However, the processability of polypropylene is often unfavourable as the melt strength of polypropylene is low in comparison to those of polyethylene. Moreover, the brittleness under high speed processing as well as low temperature impact loading limits the use of polypropylene in numerous applications. Impact behaviour frequently is improved by incorporating ethylene propylene rubber. For broadening the applicability polypropylene is often modified by various measures such post reactor peroxide treatment promoting branching reactions. Promoting of branching by peroxide treatment unfortunately is always accompanied by beta scission as a side reaction, i.e. significant degradation of the polypropylene. The main reaction leading to higher degree of branching nevertheless is highly desirable as the resulting structure is responsible for flow stabilization of the molten polypropylene with higher stress. This behaviour is well-known as strain hardening.

Polypropylene having strain hardening behaviour is for example described in EP 1 903 070. EP 1 903 070 reports polypropylene having a high melt strength due to a large number of side chains (branched polypropylene) leading also to relatively high stiffness. The use of the specific polypropylene is only described for the matrix as far as heterophasic polypropylenes are concerned.

EP 1 847 555 relates to multi-branched polypropylene homo- and copolymers. The material shows extensional melt flow properties leading to high stability in extrusion processes. The use of the specific polypropylene again is only described for the matrix in a heterophasic polypropylene.

Cables comprising a multi-branched polypropylene in monophasic form are known from EP 1 903 579.

WO 2009/047188 relates to soft polypropylene composition with a soft touch feeling.

WO 01/36502 provides a method of preparing a polypropylene heterophasic copolymer, which involves visbreaking a polypropylene heterophasic copolymer with an optimised rubber composition.

A polyolefin composition containing a heterophasic propylene copolymer, a polymeric nucleating agent and a low-density polyethylene is disclosed in EP 1 801 156.

However, for various applications a soft material having a relatively high melt flow rate is desired. Moreover, most of these applications require relatively high melting temperature, which insofar calls for a relatively low amount of the xylene soluble fraction. Such a low amount of the xylene soluble fraction usually does not yield the desired softness particularly when the polypropylene is modified to have long chain branching.

The present invention is based on the finding that the above object can be achieved if a propylene random copolymer as a matrix phase is combined with a dispersed phase comprising an ethylene-propylene copolymer rubber with a low amount of ethylene monomer units to yield a heterophasic propylene random copolymer resin having a homogeneous branching structure showing moderate strain hardening factors.

Hence, the present invention provides

a heterophasic polypropylene resin having

-   -   a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min, determined         according to ISO 1133, and

a propylene random copolymer matrix phase (A), and

an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase,

wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) being present in the resin in an amount of 15 to 45 wt %; whereby said fraction soluble in p-xylene at 25° C. (XCS fraction) has an ethylene content of 25 wt % or lower

and

a fraction insoluble in p-xylene at 25° C. (XCU fraction),

said heterophasic polypropylene resin being characterised by a strain hardening factor (SHF) of 1.7 to 4.0 when measured at a strain rate of 3.0 s⁻¹ and a Hencky strain of 3.0.

The present invention further provides

a heterophasic polypropylene resin

-   -   having a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min,         determined according to ISO 1133, and having a tensile modulus         of 450 MPa or lower when measured according to ISO 527-2 on an         injection moulded test specimen of type 1A prepared according to         ISO 1872-2 at a temperature of 23° C. and an elongation rate of         1 mm/min, and

a propylene random copolymer matrix phase (A), and

an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase,

wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) which is present in the resin in an amount of 15 to 45 wt %, whereby said fraction soluble in p-xylene at 25° C. (XCS fraction) has an ethylene content of 25 wt % or lower and a molecular weight distribution Mw/Mn of 1.0 to 4.0; and

a fraction insoluble in p-xylene at 25° C. (XCU fraction).

The heterophasic polypropylene resin according to the invention surprisingly shows a unique balance of high softness and at the same time moderate strain hardening properties accompanied with relatively high melt flow rate and excellent mechanical properties already at comparatively small amounts of the xylene soluble fraction (XCS fraction).

Particularly it has been found that the heterophasic polypropylenes resins according to the present invention have a specific degree and structure of branching not being observed before. The moderate degree and homogeneous nature of long chain branching is reflected by moderate strain hardening factors at all Hencky strains. This specific structure opens new applications in the fields of blow-fill-seal (BFS), extrusion blow moulding (EBM) and blown film (BF) applications.

The term “heterophasic polypropylene resin” used herein denotes a crystalline isotactic polypropylene matrix phase in which an amorphous phase is dispersed.

Crystalline matrix phase denotes a phase wherein an amount of at least 90 wt %, more preferably of at least 93 wt % and most preferably of at least 95 wt % is insoluble in p-xylene at 25° C.

Amorphous phase denotes a phase wherein an amount of at least 90 wt %, more preferably of at least 93 wt % and most preferably of at least 95 wt % is soluble in p-xylene at 25° C.

The fraction soluble in p-xylene (XCS fraction) denotes as the fraction of the heterophasic polypropylene resin that is soluble in p-xylene at 25° C. representing for the most part amorphous ethylene-propylene copolymer.

The fraction insoluble in p-xylene at 25° C. (XCU fraction) is meant to be the fraction of the heterophasic polypropylene resin that is not soluble in p-xylene at 25° C. representing for the most part the isotactic propylene random copolymer matrix phase.

Catalyst denotes the organo-metallic compound containing the reaction centre of the polymerisation.

Catalyst system denotes the mixture of the catalyst, the optional cocatalyst and an optional support.

The strain hardening factor is defined as

${S\; H\; F} = {\frac{\eta_{E}^{+}\left( {t,\overset{.}{ɛ}} \right)}{\eta_{LVE}^{+}(t)} = \frac{\eta_{E}^{+}\left( {t,\overset{.}{ɛ}} \right)}{3{\eta^{+}(t)}}}$

wherein

η_(E) ⁺(t,{dot over (ε)}) is the uniaxial extensional viscosity; and

η_(LVE) ⁺(t) is three times the time dependent shear viscosity η⁺(t) in the linear range of deformation.

The determination of the linear viscoelastic envelop in extension η_(LVE) ⁺(t), using IRIS Rheo Hub 2008, requires the calculation of the discrete relaxation time spectrum from the storage and loss modulus data (G′, G″ (ω)). The linear viscoelastic data (G′, G″ (ω)) is obtained by frequency sweep measurements. The underlying calculation principles used for the determination of the discrete relaxation spectrum are described in Baumgärtel M, Winter H H, “Determination of the discrete relaxation and retardation time spectra from dynamic mechanical data”, Rheol Acta 28:511519 (1989) which is incorporated by reference.

IRIS RheoHub 2008 expresses the relaxation time spectrum as a sum of N Maxwell modes

${\overset{\bullet}{G}(t)} = {G_{e} \cdot {\sum\limits_{1}^{N}{g_{i} \cdot {\mathbb{e}}^{- \frac{t}{\lambda_{i}}}}}}$ wherein g_(i) and λ_(i) are material parameters and G_(e) is the equilibrium modulus.

The choice for the maximum number of modes, N used for determination of the discrete relaxation spectrum, is done by using the option “optimum” from IRIS RheoHub 2008. The equilibrium modulus G_(e) is set at zero. The non-linear fitting used to obtain η_(LVE) ⁺(t) is performed on IRIS Rheo Hub 2008, using the Doi-Edwards model.

Propylene matrix phase (A) may consist of a single propylene random copolymer, but matrix phase (A) may also comprise a mixture of different propylene homo- or copolymers comprising at least one propylene random copolymer. This also applies for all preferred embodiments of component (A). In a preferred embodiment matrix phase (A) consists of a single propylene random copolymer.

The ethylene-propylene copolymer rubber phase (B) may consist of a single compound, but may also comprise a mixture of different compounds. This also applies for all preferred embodiments of component (B).

The XCU fraction preferably has a comonomer content of 1.5 to 5 wt %, more preferably of 1.5 to 4.5 wt %, and most preferably of 1.5 to 4.3 wt %.

Furthermore, the comonomer units in the XCU fraction are preferably selected from a group consisting of alpha-olefins having 2 and/or from 4 to 12 carbon atoms. It is especially preferred that the comonomer units in the XCU material comprise at least 90% ethylene comonomer units.

It is preferred that the fraction insoluble in p-xylene at 25° C. (XCU) is present in the polypropylene resin in an amount of 55 to 85 wt %, more preferably of 55 to 77 wt %, and most preferably of 59 to 74 wt %.

The XCU fraction preferably has an amount of comonomer units of 5 wt % or lower, more preferably of 4.5 wt % or lower, and most preferably of 4.3 wt % or lower.

Furthermore, the XCU fraction preferably has a weight average molecular weight (M_(w)) of 120 to 350 kg/mol, more preferably of 170 to 300 kg/mol, and most preferably of 200 to 275 kg/mol, measured by GPC according to ISO 16014-1 and -4.

In addition, the XCU fraction preferably has an intrinsic viscosity of 0.5 to 3.5 dl/g, more preferably of 1.0 to 3.0 dl/g and most preferably of 1.7 to 2.1 dl/g, determined according to DIN EN ISO 1628-1 and -3.

The XCU phase preferably has a melting temperature (T_(m)) of 130 to 153° C., more preferably of 134 to 151° C. and most preferably of 138 to 149° C., determined according to ISO 11357-3.

Furthermore, the XCU phase preferably has a crystallisation temperature (T_(c)) of 90 to 120° C., more preferably of 95 to 115° C., and most preferably of 100 to 113° C., determined according to ISO 11357-3.

The fraction soluble in p-xylene at 25° C. (XCS) is present in the heterophasic polypropylene resin in an amount of 15 to 45 wt %, preferably of 23 to 45 wt %, and more preferably of 26 to 41 wt %.

According to a first embodiment, the fraction soluble in p-xylene at 25° C. (XCS) is present in the heterophasic polypropylene resin in an amount of 15 to 30 wt %. In this embodiment, the heterophasic polypropylene resin is brittle in the IFW test and exhibits a IFW at −20° C. of below 500N.

According to a second embodiment, the fraction soluble in p-xylene at 25° C. (XCS) is present in the heterophasic polypropylene resin in an amount of above 30 to 45 wt %. In this embodiment, the heterophasic polypropylene resin results in an advantageous Charpy notched impact strength at −20° C. and exhibits a IFW at −20° C. of 3500-4500N.

The XCS fraction has an amount of ethylene comonomer units of 25 wt % or lower. Preferably, the phase has an amount of ethylene comonomer units of 10 to 25 wt %, more preferably of 12 to 20 wt %, and most preferably of 13 to 17 wt %.

The fraction soluble in p-xylene at 25° C. (XCS) has a molecular weight distribution (M_(w)/M_(n)) of 1.0 to 4.0, preferably of 2.0 to 3.7 and more preferably of 2.8 to 3.4.

Furthermore, the XCS fraction preferably has a weight average molecular weight (M_(w)) of 170 to 260 kg/mol, more preferably of 180 to 250 kg/mol, and most preferably of 190 to 210 kg/mol, measured by GPC according to ISO 16014-1 and -4.

Furthermore, the XCS fraction preferably has a number average molecular weight (M_(n)) of 30 to 160 kg/mol, more preferably of 40 to 140 kg/mol, and most preferably of 60 to 90 kg/mol, measured by GPC according to ISO 16014-1 and -4.

In addition, the XCS fraction preferably has an intrinsic viscosity of 1.0 to 2.5 dl/g, more preferably of 1.2 to 2.0 dl/g and most preferably of 1.4 to 1.7 dl/g, determined according to DIN EN ISO 1628-1 and -3.

The XCS fraction preferably has a melting temperature (T_(m)) of 43 to 60° C., more preferably of 47 to 57° C. and most preferably of 50 to 55° C., determined according to ISO 11357-3.

The heterophasic polypropylene resin according to the invention has a melt flow rate MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min, preferably of at least 2.0 g/10 min, more preferably of at least 2.1 g/10 min and most preferably of at least 2.2 g/10 min, determined according to ISO 1133.

Further, the melt flow rate MFR (2.16 kg, 230° C.) of the heterophasic polypropylene resin according to the invention is not more than 100 g/10 min, preferably not more than 50 g/10 min, more preferably not more than 9.5 g/10 min, even more preferably not more than 8.0 g/10 min and most preferably not more than 6.5 g/10 min, determined according to ISO 1133.

The heterophasic polypropylene resin according to the invention preferably has a strain-hardening factor (SHF) of 1.2 to 2.1, more preferably of 1.5 to 2.1, and most preferably of 1.6 to 2.1 when measured at strain rates of 1 s⁻¹ and a Hencky strain of 2.5.

The heterophasic polypropylene resin according to the invention preferably has a strain-hardening factor (SHF) of 1.2 to 2.1, more preferably of 1.5 to 2.1, and most preferably of 1.6 to 2.1 when measured at strain rates of 3 s⁻¹ and a Hencky strain of 2.5.

The heterophasic polypropylene resin according to the invention preferably has a strain-hardening factor (SHF) of 1.2 to 4.1, more preferably of 1.6 to 3.2, and most preferably of 2.1 to 2.8 when measured at strain rates of 1 s⁻¹ and a Hencky strain of 3.0.

The heterophasic polypropylene resin according to the invention has a strain-hardening factor (SHF) of 1.7 to 4.0, preferably of 1.6 to 3.2, and more preferably of 2.1 to 2.8 when measured at strain rates of 3 s⁻¹ and a Hencky strain of 3.0.

The heterophasic polypropylene resin according to the invention further preferably has a strain hardening factor (SHF) with low standard deviation of less than 3% at a Hencky strain of 1.5, more preferably of less than 2.5% and most preferably of less than 2.3%.

The heterophasic polypropylene resin according to the invention further preferably has a strain hardening factor (SHF) with low standard deviation of less than 6.2% at a Hencky strain of 2.0, more preferably of less than 6.0% and most preferably of less than 5.8%.

The heterophasic polypropylene resin according to the invention further preferably has a strain hardening factor (SHF) with low standard deviation of less than 8% at a Hencky strain of 2.5, more preferably of less than 7.5% and most preferably of less than 7.1%.

The heterophasic polypropylene resin according to the invention further preferably has a strain hardening factor (SHF) with low standard deviation of less than 12% at a Hencky strain of 3.0, more preferably of less than 10% and most preferably of less than 9.4%.

The heterophasic polypropylene resin according to the invention preferably has a melting temperature (T_(m)) of 133 to 150° C., more preferably of 134 to 148° C. and most preferably of 135 to 147° C., determined according to ISO 11357-3.

Furthermore, the heterophasic polypropylene resin according to the invention preferably has a crystallisation temperature (T_(c)) of 90 to 120° C., more preferably of 95 to 115° C., and most preferably of 98 to 111° C., determined according to ISO 11357-3.

The heterophasic polypropylene resin according to the invention preferably has a tensile modulus of 450 MPa and lower, more preferably of 150 to 450 MPa, even more preferably of 180 to 420 MPa, and most preferably of 200 to 400 MPa, determined according to ISO 527-2.

Furthermore, the heterophasic polypropylene resin according to the invention preferably has an elongation at break of 400 to 700%, more preferably of 430 to 650% and more preferably of 450 to 630%, determined according to ISO 527-2.

The heterophasic polypropylene resin according to the invention preferably has a Charpy notched impact strength at 23° C. of at least 90 kJ/m², more preferably of 80 to 150 kJ/m², even more preferably of 85 to 130 kJ/m² and most preferably of 90 to 120 kJ/m², determined according to ISO 179-1/1eA.

Additionally, the heterophasic polypropylene resin preferably has a Charpy notched impact strength at −20° C. of at least 10 kJ/m², more preferably of 10 to 150 kJ/m², even more preferably of 10 to 130 kJ/m² and most preferably of 10 to 110 kJ/m², determined according to ISO 179-1/1eA.

The heterophasic polypropylene resin according to the invention preferably withstands a maximum instrumented falling weight force at −20° C. of at least 250 N, more preferably of more preferably of 200 to 5000 N, and most preferably of 250 to 4500 N, determined according to ISO 6603-2.

The heterophasic polypropylene resin according to the invention preferably has a maximum instrumented falling weight deflection at −20° C. of 6 to 18 mm, more preferably of 8 to 16 mm, and most preferably of 10 to 14 mm, determined according to ISO 6603-2.

In a preferred embodiment the heterophasic polypropylene resin is produced in a multi-stage process. Multistage processes include also bulk/gas phase reactors known as multizone gas phase reactors.

The heterophasic polypropylene resin according to this invention is obtainable by a catalyst system comprising an asymmetric catalyst, whereby the catalyst system has a porosity of less than 1.40 ml/g, more preferably less than 1.30 ml/g and most preferably less than 1.00 ml/g. The porosity has been measured according to DIN 66135 (N₂). In another preferred embodiment the porosity is below detection limit when determined with the method applied according to DIN 66135.

The catalyst system may further comprise an activator as a cocatalyst, as described in WO 03/051934, which is enclosed herein by reference.

An asymmetric catalyst according to this invention is a catalyst comprising at least two organic ligands which differ in their chemical structure.

Furthermore it is preferred, that the catalyst system has a surface area of less than 25 m²/g, yet more preferred less than 20 m²/g, still more preferred less than 15 m²/g, yet still less than 10 m²/g and most preferred less than 5 m²/g. The surface area according to this invention is measured according to ISO 9277 (N₂).

It is in particular preferred that the catalytic system according to this invention comprises an asymmetric catalyst, i.e. a catalyst as defined below, and has porosity not detectable when applying the method according to DIN 66135 (N₂) and has a surface area measured according to ISO 9277 (N₂) less than 5 m²/g.

Preferably, the asymmetric catalyst employed comprises an organo-metallic compound of a transition metal of group 3 to 10 or the periodic table (IUPAC) or of an actinide or lanthanide.

The asymmetric catalyst is more preferably of a transition metal compound of formula (I) (L)_(m)R_(n)MX_(q)  (I)

wherein

M is a transition metal of group 3 to 10 or the periodic table (IUPAC), or of an actinide or lanthanide,

each X is independently a monovalent anionic ligand, such as σ-ligand,

each L is independently an organic ligand which coordinates to M,

R is a bridging group linking two ligands L,

m is 2 or 3,

n is 0 or 1,

q is 1, 2 or 3,

m+q is equal to the valency of the metal, and

with the proviso that at least two ligands “L” are of different chemical structure.

Said asymmetric catalyst is preferably a single site catalyst (SSC).

In a more preferred definition, each “L” is independently

(a) a substituted or unsubstituted cycloalkyldiene, i.e. a cyclopentadiene, or a mono-, bi- or multifused derivative of a cycloalkyldiene, i.e. a cyclopentadiene, which optionally bear further substituents and/or one or more hetero ring atoms from a Group 13 to 16 of the Periodic Table (IUPAC); or

(b) an acyclic, to η¹- to η⁴- or η⁶-ligand composed of atoms from Groups 13 to 16 of the Periodic Table, and in which the open chain ligand may be fused with one or two, preferably two, aromatic or non-aromatic rings and/or bear further substituents; or

(c) a cyclic σ-, η¹- to η⁴- or η⁶-, mono-, bi- or multidentate ligand composed of unsubstituted or substituted mono-, bi- or multicyclic ring systems selected from aromatic or non-aromatic or partially saturated ring systems and containing carbon ring atoms and optionally one or more heteroatoms selected from Groups 15 and 16 of the Periodic Table.

The term “σ-ligand” is understood in the whole description in a known manner, i.e. a group bonded to the metal at one or more places via a sigma bond. A preferred monovalent anionic ligand is halogen, in particular chlorine (Cl).

In a preferred embodiment, the asymmetric catalyst is preferably of a transition metal compound of formula (I) (L)_(m)R_(n)MX_(q)  (I)

wherein

M is a transition metal of group 3 to 10 or the periodic table (IUPAC), or of an actinide or lanthanide,

each X is independently a monovalent anionic ligand, such as σ-ligand,

each L is independently an organic ligand which coordinates to M, wherein the organic ligand is an unsaturated organic cyclic ligand, more preferably a substituted or unsubstituted, cycloalkyldiene, i.e. a cyclopentadiene, or a mono-, bi- or multifused derivative of a cycloalkyldiene, i.e. a cyclopentadiene, which optionally bear further substituents and/or one or more hetero ring atoms from a Group 13 to 16 of the Periodic Table (IUPAC),

R is a bridging group linking two ligands L,

m is 2 or 3,

n is 0 or 1,

q is 1, 2 or 3,

m+q is equal to the valency of the metal, and

with the proviso that at least two ligands “L” are of different chemical structure.

According to a preferred embodiment said asymmetric catalyst compound (I) is a group of compounds known as metallocenes. Said metallocenes bear at least one organic ligand, generally 1, 2 or 3, e.g. 1 or 2, which is η-bonded to the metal, e.g. a η²⁻⁶-ligand, such as a η⁵-ligand. Preferably, a metallocene is a Group 4 to 6 transition metal, more preferably zirconium, which contains at least one η⁵-ligand.

Preferably the asymmetric catalyst compound has a formula (II): (Cp)_(m)R_(n)MX_(q)  (II)

wherein

M is Zr, Hf or Ti, preferably Zr

each X is independently a monovalent anionic ligand, such as σ-ligand,

each Cp is independently an unsaturated organic cyclic ligand which coordinates to M,

R is a bridging group linking two ligands L,

m is 2,

n is 0 or 1, more preferably 1,

q is 1, 2 or 3, more preferably 2,

m+q is equal to the valency of the metal, and

at least one Cp-ligand, preferably both Cp-ligands, is(are) selected from the group consisting of unsubstituted cyclopenadienyl, unsubstituted indenyl, unsubstituted tetrahydroindenyl, unsubstituted fluorenyl, substituted cyclopentadienyl, substituted indenyl, substituted tetrahydroindenyl, and substituted fluorenyl,

with the proviso in case both Cp-ligands are selected from the above stated group that both Cp-ligands must chemically differ from each other.

Preferably, the asymmetric catalyst is of formula (II) indicated above, wherein

M is Zr

each X is Cl,

n is 1, and

q is 2.

Preferably both Cp-ligands have different residues to obtain an asymmetric structure.

Preferably, both Cp-ligands are selected from the group consisting of substituted cyclopentadienyl-ring, substituted indenyl-ring, substituted tetrahydroindenyl-ring, and substituted fluorenyl-ring wherein the Cp-ligands differ in the substituents bonded to the rings.

The optional one or more substituent(s) bonded to cyclopentadienyl, indenyl, tetrahydroindenyl, or fluorenyl may be independently selected from a group including halogen, hydrocarbyl (e.g. C₁-C₂₀-alkyl, C₂-C₂₀-alkenyl, C₂-C₂₀-alkynyl, C₃-C₁₂-cycloalkyl, C₆-C₂₀-aryl or C₇-C₂₀-arylalkyl), C₃-C₁₂-cycloalkyl which contains 1, 2, 3 or 4 heteroatom(s) in the ring moiety, C₆-C₂₀-heteroaryl, C₁-C₂₀-haloalkyl, —SiR″₃, —OSiR″₃, —SR″, —PR″₂ and —NR″₂, wherein each R″ is independently a hydrogen or hydrocarbyl, e.g. C₁-C₂₀-alkyl, C₂-C₂₀-alkenyl, C₂-C₂₀-alkynyl, C₃-C₁₂-cycloalkyl or C₆-C₂₀-aryl.

More preferably both Cp-ligands are indenyl moieties wherein each indenyl moiety bear one or two substituents as defined above. More preferably each Cp-ligand is an indenyl moiety bearing two substituents as defined above, with the proviso that the substituents are chosen in such are manner that both Cp-ligands are of different chemical structure, i.e both Cp-ligands differ at least in one substituent bonded to the indenyl moiety, in particular differ in the substituent bonded to the five member ring of the indenyl moiety.

Still more preferably both Cp are indenyl moieties wherein the indenyl moieties comprise at least at the five membered ring of the indenyl moiety, more preferably at 2-position, a substituent selected from the group consisting of alkyl, such as C₁-C₆ alkyl, e.g. methyl, ethyl, isopropyl, and trialkyloxysiloxy, wherein each alkyl is independently selected from C₁-C₆ alkyl, such as methyl or ethyl, with proviso that the indenyl moieties of both Cp must chemically differ from each other, i.e. the indenyl moieties of both Cp comprise different substituents.

Still more preferred both Cp are indenyl moieties wherein the indenyl moieties comprise at least at the six membered ring of the indenyl moiety, more preferably at 4-position, a substituent selected from the group consisting of a C₆-C₂₀ aromatic ring moiety, such as phenyl or naphthyl, preferably phenyl, which is optionally substituted with one or more substituents, such as C₁-C₆ alkyl, and a heteroaromatic ring moiety, with proviso that the indenyl moieties of both Cp must chemically differ from each other, i.e. the indenyl moieties of both Cp comprise different substituents.

Yet more preferably both Cp are indenyl moieties wherein the indenyl moieties comprise at the five membered ring of the indenyl moiety, more preferably at 2-position, a substituent and at the six membered ring of the indenyl moiety, more preferably at 4-position, a further substituent, wherein the substituent of the five membered ring is selected from the group consisting of alkyl, such as C₁-C₆ alkyl, e.g. methyl, ethyl, isopropyl, and trialkyloxysiloxy, wherein each alkyl is independently selected from C₁-C₆ alkyl, such as methyl or ethyl, and the further substituent of the six membered ring is selected from the group consisting of a C₆-C₂₀ aromatic ring moiety, such as phenyl or naphthyl, preferably phenyl, which is optionally substituted with one or more substituents, such as C₁-C₆ alkyl, and a heteroaromatic ring moiety, with proviso that the indenyl moieties of both Cp must chemically differ from each other, i.e. the indenyl moieties of both Cp comprise different substituents. It is in particular preferred that both Cp are indenyl rings comprising two substituents each and differ in the substituents bonded to the five membered ring of the indenyl rings.

Concerning the moiety “R” it is preferred that “R” has the formula (III) —Y(R′)₂—  (III)

wherein

Y is C, Si or Ge, and

R′ is C₁ to C₂₀ alkyl, C₆-C₁₂ aryl, or C₇-C₁₂ arylalkyl.

In case both Cp-ligands of the asymmetric catalyst as defined above, in particular case of two indenyl moieties, are linked with a bridge member R, the bridge member R is typically placed at 1-position. The bridge member R may contain one or more bridge atoms selected from e.g. C, Si and/or Ge, preferably from C and/or Si. One preferable bridge R is —Si(R′)₂—, wherein R′ is selected independently from one or more of e.g. C₁-C₁₀ alkyl, C₁-C₂₀ alkyl, such as C₆-C₁₂ aryl, or C₇-C₄₀, such as C₇-C₁₂ arylalkyl, wherein alkyl as such or as part of arylalkyl is preferably C₁-C₆ alkyl, such as ethyl or methyl, preferably methyl, and aryl is preferably phenyl. The bridge —Si(R′)₂— is preferably e.g. —Si(C₁-C₆ alkyl)₂-, —Si(phenyl)₂- or —Si(C₁-C₆ alkyl)(phenyl)-, such as —Si(Me)₂-.

In a preferred embodiment the asymmetric catalyst is defined by the formula (IV) (Cp)₂R₁ZrX₂  (IV)

wherein

each X is independently a monovalent anionic ligand, such as σ-ligand, in particular halogen

both Cp coordinate to M and are selected from the group consisting of unsubstituted cyclopentadienyl, unsubstituted indenyl, unsubstituted tetrahydroindenyl, unsubstituted fluorenyl, substituted cyclopenadienyl, substituted indenyl, substituted tetrahydroindenyl, and substituted fluorenyl,

with the proviso that both Cp-ligands must chemically differ from each other, and

R is a bridging group linking two ligands L,

wherein R is defined by the formula (III) —Y(R′)₂—  (III)

wherein

Y is C, Si or Ge, and

R′ is C₁ to C₂₀ alkyl, C₆-C₁₂ aryl, or C₇-C₁₂ arylalkyl.

More preferably the asymmetric catalyst is defined by the formula (IV), wherein both Cp are selected from the group consisting of substituted cyclopenadienyl, substituted indenyl, substituted tetrahydroindenyl, and substituted fluorenyl.

Yet more preferably the asymmetric catalyst is defined by the formula (IV), wherein both Cp are selected from the group consisting of substituted cyclopentadienyl, substituted indenyl, substituted tetrahydroindenyl, and substituted fluorenyl with the proviso that both Cp-ligands differ in the substituents, i.e. the substituents as defined above, bonded to cyclopentadienyl, indenyl, tetrahydroindenyl, or fluorenyl.

Still more preferably the asymmetric catalyst is defined by the formula (IV), wherein both Cp are indenyl and both indenyl differ in one substituent, i.e. in a substituent as defined above bonded to the five member ring of indenyl.

It is in particular preferred that the asymmetric catalyst is a non-silica supported catalyst as defined above, in particular a metallocene catalyst as defined above.

In a preferred embodiment the asymmetric catalyst is dimethylsilyl [(2-methyl-(4′-tert.butyl)-4-phenyl-indenyl)(2-isopropyl-(4′-tert.butyl)-4-phenyl-indenyl)]zirconium dichloride. More preferred said asymmetric catalyst is not silica supported.

The above described asymmetric catalyst components are prepared according to the methods described in WO 01/48034.

It is in particular preferred that the asymmetric catalyst system is obtained by the emulsion solidification technology as described in WO 03/051934. This document is herewith included in its entirety by reference. Hence the asymmetric catalyst is preferably in the form of solid catalyst particles, obtainable by a process comprising the steps of

-   -   a) preparing a solution of one or more asymmetric catalyst         components;     -   b) dispersing said solution in a solvent immiscible therewith to         form an emulsion in which said one or more catalyst components         are present in the droplets of the dispersed phase,     -   c) solidifying said dispersed phase to convert said droplets to         solid particles and optionally recovering said particles to         obtain said catalyst.

Preferably a solvent, more preferably an organic solvent, is used to form said solution. Still more preferably the organic solvent is selected from the group consisting of a linear alkane, cyclic alkane, linear alkene, cyclic alkene, aromatic hydrocarbon and halogen-containing hydrocarbon.

Moreover the immiscible solvent forming the continuous phase is an inert solvent, more preferably the immiscible solvent comprises a fluorinated organic solvent and/or a functionalized derivative thereof, still more preferably the immiscible solvent comprises a semi-, highly- or perfluorinated hydrocarbon and/or a functionalized derivative thereof. It is in particular preferred, that said immiscible solvent comprises a perfluorohydrocarbon or a functionalized derivative thereof, preferably C₃-C₃₀ perfluoroalkanes, -alkenes or -cycloalkanes, more preferred C₄-C₁₀ perfluoro-alkanes, -alkenes or -cycloalkanes, particularly preferred perfluorohexane, perfluoroheptane, perfluorooctane or perfluoro(methylcyclohexane) or a mixture thereof.

Furthermore it is preferred that the emulsion comprising said continuous phase and said dispersed phase is a bi- or multiphasic system as known in the art. An emulsifier may be used for forming the emulsion. After the formation of the emulsion system, said catalyst is formed in situ from catalyst components in said solution.

In principle, the emulsifying agent may be any suitable agent which contributes to the formation and/or stabilization of the emulsion and which does not have any adverse effect on the catalytic activity of the catalyst. The emulsifying agent may e.g. be a surfactant based on hydrocarbons optionally interrupted with (a) heteroatom(s), preferably halogenated hydrocarbons optionally having a functional group, preferably semi-, highly- or perfluorinated hydrocarbons as known in the art. Alternatively, the emulsifying agent may be prepared during the emulsion preparation, e.g. by reacting a surfactant precursor with a compound of the catalyst solution. Said surfactant precursor may be a halogenated hydrocarbon with at least one functional group, e.g. a highly fluorinated C₁ to C₃₀ alcohol, which reacts e.g. with a cocatalyst component, such as aluminoxane.

In principle any solidification method can be used for forming the solid particles from the dispersed droplets. According to one preferable embodiment the solidification is effected by a temperature change treatment. Hence the emulsion subjected to gradual temperature change of up to 10° C./min, preferably 0.5 to 6° C./min and more preferably 1 to 5° C./min. Even more preferred the emulsion is subjected to a temperature change of more than 40° C., preferably more than 50° C. within less than 10 seconds, preferably less than 6 seconds.

The recovered particles have preferably an average size range of 5 to 200 μm, more preferably 10 to 100 μm.

Moreover, the form of solidified particles have preferably a spherical shape, a predetermined particles size distribution and a surface area as mentioned above of preferably less than 25 m²/g, still more preferably less than 20 m²/g, yet more preferably less than 15 m²/g, yet still more preferably less than 10 m²/g and most preferably less than 5 m²/g, wherein said particles are obtained by the process as described above.

For further details, embodiments and examples of the continuous and dispersed phase system, emulsion formation method, emulsifying agent and solidification methods reference is made e.g. to the above cited international patent application WO 03/051934.

Preferred as cocatalysts for metallocenes and non-metallocenes, if desired, are the aluminoxanes, in particular the C₁-C₁₀-alkylaluminoxanes, most particularly methylaluminoxane (MAO). Such aluminoxanes can be used as the sole cocatalyst or together with other cocatalyst(s). Thus besides or in addition to aluminoxanes, other cation complex forming catalysts activators can be used. Said activators are commercially available or can be prepared according to the prior art literature.

Further aluminoxane cocatalysts are described i.a. in WO 94/28034 which is incorporated herein by reference. These are linear or cyclic oligomers of having up to 40, preferably 3 to 20, —(Al(R″′)O)— repeat units (wherein R″′ is hydrogen, C₁-C₁₀-alkyl (preferably methyl) or C₆-C₁₈-aryl or mixtures thereof).

The use and amounts of such activators are within the skills of an expert in the field. As an example, with the boron activators, 5:1 to 1:5, preferably 2:1 to 1:2, such as 1:1, ratio of the transition metal to boron activator may be used. In case of preferred aluminoxanes, such as methylaluminumoxane (MAO), the amount of Al, provided by aluminoxane, can be chosen to provide a molar ratio of Al:transition metal e.g. in the range of 1 to 10 000, suitably 5 to 8000, preferably 10 to 7000, e.g. 100 to 4000, such as 1000 to 3000. Typically in case of solid (heterogeneous) catalyst the ratio is preferably below 500.

The quantity of cocatalyst to be employed in the catalyst of the invention is thus variable, and depends on the conditions and the particular transition metal compound chosen in a manner well known to a person skilled in the art.

Any additional components to be contained in the solution comprising the organotransition compound may be added to said solution before or, alternatively, after the dispersing step.

Furthermore, the present invention relates to the use of the above-defined catalyst system for the production a heterophasic polypropylene resin according to this invention.

The present invention relates to a heterophasic polypropylene composition comprising the inventive heterophasic polypropylene resin and modifiers in an amount of up to 10 wt % as well as additives in an amount up to 1 wt % with respect to the total heterophasic polypropylene composition. These modifiers and/or additives may be included during the polymerisation process or after the polymerisation by melt mixing. Suitable modifiers include other thermoplastics like polyethylene homo- or copolymers, poly-1-butene, poly-4-methylpentene-1 and/or thermoplastic elastomers like ethylene-propylene rubber or styrene elastomers as well as mineral fillers like talc or calcium carbonate. Suitable additives include stabilizers, lubricants, nucleating agents, pigments and foaming agents.

The present invention further relates to a process for producing the heterophasic polypropylene according to the invention, wherein the propylene copolymer matrix phase (A) is prepared in a first stage and the ethylene-propylene copolymer rubber phase (B) is prepared in a second stage in the presence of the first stage product. The multistage process of the invention may include bulk reactors or gas phase reactors in any of the polymerisation stages.

Thereby it is preferred that the propylene random copolymer matrix (A) is produced in a bulk reactor and afterwards transferred to a gas phase reactor in which the ethylene-propylene rubber phase (B) is produced in the presence of component (A).

Preferably, in the process for producing the heterophasic polypropylene resin, the same catalyst is used for the production of the matrix and the dispersed phase.

Preferably, in the process the catalyst is capable of producing a fraction being soluble in p-xylene at 25° C. having a molecular weight distribution Mw/Mn of 1.0 to 4.0.

Preferably, in the process the heterophasic polypropylene resin is produced in a multistage process involving at least two reactors, whereby one reactor is operated with a C3/C2 weight ratio of from 68/32 to 90/10.

The bulk polymerisations are preferably performed in a so-called loop reactor.

A preferred multistage process is a “loop-gas phase”-process, such as developed by Borealis A/S, Denmark (known as Borstar® technology) described e.g. in patent literature, such as in EP 0 887 379 or in WO 92/12182.

Optionally, the process may also comprise a pre-polymerisation step in a manner known in the field and which may precede the first polymerisation step (a).

The process is preferably a continuous process.

Preferably, in the process for producing the propylene random copolymer as defined above the conditions for the bulk reactor of step (a) may be as follows:

-   -   the temperature is within the range of 40° C. to 110° C.,         preferably between 60° C. and 100° C., most preferably 70 to 90°         C.,     -   the pressure is within the range of 20 bar to 80 bar, preferably         between 30 bar to 60 bar,     -   hydrogen can be added for controlling the molar mass in a manner         known per se.

Subsequently, the reaction mixture from the bulk (loop) reactor (step a) is transferred to the gas phase reactor, i.e. to step (b), whereby the conditions in step (b) are preferably as follows:

-   -   the temperature is within the range of 50° C. to 130° C.,         preferably between 60° C. and 100° C.,     -   the pressure is within the range of 5 bar to 50 bar, preferably         between 15 bar to 35 bar,     -   hydrogen can be added for controlling the molar mass in a manner         known per se.

The residence time can vary in both reactor zones. In one embodiment of the process for producing the propylene polymer the residence time in bulk reactor, e.g. loop is in the range 0.5 to 5 hours, e.g. 0.5 to 2 hours and the residence time in gas phase reactor will generally be 1 to 8 hours.

If desired, the polymerisation may be effected in a known manner under supercritical conditions in the bulk, preferably loop reactor, and/or as a condensed mode in the gas phase reactor.

In a further embodiment, the components (A) and (B) are preferably polymerised separately and compounded by melt-mixing.

Preferably, the heterophasic polypropylene resin is produced according to any of the above embodiments of the process.

Preferably, the ethylene-propylene copolymer rubber phase is produced according to any of the above embodiments of the process.

Further, the present invention relates to an article comprising the heterophasic polypropylene resin according to the invention.

In the following, the present invention is described by way of examples.

EXAMPLES 1. Methods

a) Melt Flow Rate

The melt flow rate (MFR) is determined according to ISO 1133 and is indicated in g/10 min. The MFR is an indication of the flowability, and hence the processability, of the polymer. The higher the melt flow rate, the lower the viscosity of the polymer. The MFR₂ of polypropylene is determined at a temperature of 230° C. and a load of 2.16 kg.

b) Xylene Soluble Fraction

The xylene soluble fraction (XCS) as defined and described in the present invention is determined as follows: 2.0 g of the polymer were dissolved in 250 ml p-xylene at 135° C. under agitation. After 30 minutes, the solution was allowed to cool for 15 minutes at ambient temperature and then allowed to settle for 30 minutes at 25±0.5° C. The solution was filtered with filter paper into two 100 ml flasks. The solution from the first 100 ml vessel was evaporated in nitrogen flow and the residue dried under vacuum at 90° C. until constant weight is reached. The xylene soluble fraction (percent) can then be determined as follows: XCS%=(100×m ₁ ×v ₀)/(m ₀ ×v ₁), wherein m₀ designates the initial polymer amount (grams), m₁ defines the weight of residue (grams), v₀ defines the initial volume (milliliter) and v₁ defines the volume of the analysed sample (milliliter). The fraction insoluble in p-xylene at 25° C. (XCU) is then equal to 100%−XCS %.

c) Intrinsic Viscosity

The intrinsic viscosity (IV) value increases with the molecular weight of a polymer. The intrinsic viscosity of the XCU and the XCS fraction is measured in decalin at 135° C. according to DIN EN ISO 1628-1 and -3.

d) Weight Average Molecular Weight and MWD

The weight average molecular weight Mw and the molecular weight distribution (MWD=Mw/Mn wherein Mn is the number average molecular weight and Mw is the weight average molecular weight) is measured by a method based on ISO 16014-1:2003 and ISO 16014-4:2003. A Waters Alliance GPCV 2000 instrument, equipped with refractive index detector and online viscosimeter was used with 3×TSK-gel columns (GMHXL-HT) from TosoHaas and 1,2,4-trichlorobenzene (TCB, stabilized with 200 mg/L 2,6-Di tert butyl-4-methyl-phenol) as solvent at 145° C. and at a constant flow rate of 1 ml/min. 216.5 μl of sample solution were injected per analysis. The column set was calibrated using relative calibration with 19 narrow MWD polystyrene (PS) standards in the range of 0.5 kg/mol to 11 500 kg/mol and a set of well characterized broad polypropylene standards. All samples were prepared by dissolving 5-10 mg of polymer in 10 ml (at 160° C.) of stabilized TCB (same as mobile phase) and keeping for 3 hours with continuous shaking prior sampling in into the GPC instrument.

In case of PP the constants are: K: 19×10⁻³ ml/g and a: 0.725 for PP.

e) Melting and Crystallisation Temperature

The melting and crystallisation temperature T_(m) and T_(c) are determined according to ISO 11357-3 with a TA-Instruments 2920 Dual-Cell with RSC refrigeration apparatus and data station. A heating and cooling rate of 10° C./min is applied in a heat/cool/heat cycle between +23 and +210° C., the crystallisation temperature T_(c) being determined in the cooling step and the T_(m) melting temperature being determined in the second heating step.

f) Comonomer Content

Quantitative Fourier transform infrared (FTIR) spectroscopy was used to quantify the amount of comonomer. Calibration was achieved by correlation to comonomer contents determined by quantitative nuclear magnetic resonance (NMR) spectroscopy.

The calibration procedure based on results obtained from quantitative ¹³C-NMR spectroscopy was undertaken in the conventional manner well documented in the literature.

The amount of comonomer (N) was determined as weight percent (wt %) via: N=k ₁(A/R)+k ₂

wherein A is the maximum absorbance defined of the comonomer band, R the maximum absorbance defined as peak height of the reference peak and with k₁ and k₂ the linear constants obtained by calibration. The band used for ethylene content quantification is selected depending if the ethylene content is random (730 cm⁻¹) or block-like (720 cm⁻¹). The absorbance at 4324 cm⁻¹ was used as a reference band.

g) Charpy Notched Impact Strength (NIS)

Charpy impact strength was determined according to ISO 179-1eA:2000 on V-notched samples of 80×10×4 mm³ at 23° C. (Charpy impact strength (23° C.)) and −20° C. (Charpy impact strength (−20° C.)). When not otherwise stated a standard impact velocity of 2.9 m/s was used. Some of the examples were tested with a different impact velocity of 1.5 m/s.

The test specimens were prepared by injection moulding using an IM V 60 TECH machinery in line with ISO 1872-2. The melt temperature was 200° C. and the mold temperature was 40° C.

h) Instrumented Falling Weight Impact (IFW)

The instrumented falling weight impact is determined according to ISO 6603-2 with a velocity of 4.4 m/s on 60×60×2 mm³ plates at −20° C.

i) Tensile Modulus and Elongation at Break

Mechanical properties were determined according to ISO 527-2. Injection moulded specimens of type 1A were used, which were prepared according to ISO 1872-2.

Tensile modulus (in MPa) was determined according to ISO 527-2. The measurement was conducted at 23° C. temperature with an elongation rate of 1 mm/min.

The Elongation at break is the percentage elongation at the moment of rupture of the test specimen.

j) Strain Hardening Factor (SHF)

The strain hardening factor is defined as

${S\; H\; F} = {\frac{\eta_{E}^{+}\left( {t,\overset{.}{ɛ}} \right)}{\eta_{LVE}^{+}(t)} = \frac{\eta_{E}^{+}\left( {t,\overset{.}{ɛ}} \right)}{3{\eta^{+}(t)}}}$

wherein

η_(E) ⁺(t,{dot over (ε)}) is the uniaxial extensional viscosity; and η_(LVE) ⁺(t) is three times the time dependent shear viscosity η⁺(t) in the linear range of deformation. The determination of the linear viscoelastic envelop in extension η_(LVE) ⁺(t), using IRIS Rheo Hub 2008, required the calculation of the discrete relaxation time spectrum from the storage and loss modulus data (G′, G″ (ω)). The linear viscoelastic data (G′, G″ (ω)) is obtained by frequency sweep measurements undertaken at 180° C., on a Anton Paar MCR 300 coupled with 25 mm parallel plates. The underlying calculation principles used for the determination of the discrete relaxation spectrum are described in Baumgärtel M, Winter H H, “Determination of the discrete relaxation and retardation time spectra from dynamic mechanical data”, Rheol Acta 28:511519 (1989) which is incorporated by reference in its entirety.

IRIS RheoHub 2008 expresses the relaxation time spectrum as a sum of N Maxwell modes

${\overset{\bullet}{G}(t)} = {G_{e} \cdot {\sum\limits_{1}^{N}{g_{i} \cdot {\mathbb{e}}^{- \frac{t}{\lambda_{i}}}}}}$

wherein g_(i) and λ_(i) are material parameters and G_(e) is the equilibrium modulus.

The choice for the maximum number of modes, N used for determination of the discrete relaxation spectrum, is done by using the option “optimum” from IRIS RheoHub 2008. The equilibrium modulus G_(e) was set at zero.

The non-linear fitting used to obtain η_(LVE) ⁺(t) is performed on IRIS Rheo Hub 2008, using the Doi-Edwards model.

The uniaxial extensional viscosity, η_(E) ⁺(t,{dot over (ε)}) is obtained from uniaxial extensional flow measurements, conducted on an Anton Paar MCR 501 coupled with the Sentmanat extensional fixture (SER-1). The temperature for the uniaxial extensional flow measurements was set at 180° C., applying extension rates ranging from 0.3 s⁻¹ to 10 s⁻¹

and covering a range of Hencky strain ε=(l−l ₀)/l ₀,

with l₀ being the original and l the actual sample fixation length, from 0.3 to 3.0.

Particularly care was taken for the preparation of the samples for extensional flow. The samples were prepared by compression moulding at 230° C. followed by slow cooling to room temperature (forced water or air cooling were not used). This procedure allowed obtaining well shaped samples free of residual stresses. The sample was left for five minutes at the testing temperature to ensure thermal stability, before carrying out the uniaxial extensional flow measurements.

2. Compositions Comparative Examples (CE1 and CE2)

Comparative Example CE1 is the commercially available product Borsoft SA233CF (Borealis Polyolefine GmbH, Austria) being a random-heterophasic copolymer with an MFR₂ of 0.8 g/10 min, an XCS content of 28.7 wt % and a density of 900 kg/m³. Comparative Example CE2 is the commercially available product Borsoft SD233CF (Borealis Polyolefine GmbH, Austria) being a random-heterophasic copolymer with an MFR₂ of 7.0 g/10 min, an XCS content of 31.1 wt % and a density of 900 kg/m³.

Inventive Examples (−IE1, IE2, IE3, IE4 and IE5)

Catalyst:

A support-free catalyst (III) has been prepared as described in example 5 of WO 03/051934 whilst using an asymmetric metallocene dimethylsilyl [(2-methyl-(4′-tert.butyl)-4-phenyl-indenyl)(2-isopropyl-(4′-tert.butyl)-4-phenyl-indenyl)]zirconium dichloride.

Polymerisation:

Inventive examples IE1, IE2, IE3, IE4 and IE5 were prepared in a 2 bench scale reactor initially filled with N₂ at 1 bar gauge. Catalyst, minor amount of triethylaluminum and hydrogen were first added in the reactor.

Further on liquid propylene was fed and a pre-polymerization was carried out at 35° C. for 8 min. Stirring was started and the temperature was increased to a set point temperature of 70° C., cf. data table 1. At these conditions the polymerization of the matrix component was carried out. In a subsequent step in the same vessel in the presence of the matrix particles with still active catalyst a gas phase polymerization was conducted to form the ethylene-propylene dispersed phase, maintaining a fixed C3/C2 ratio [mol/mol] in the gas phase by gas chromatography (GC) control. The operating temperature in the gas phase was 85° C., cf. data table 1. At the end of the polymerisation, the reactor was vented.

After the polymerisation process the materials were pelletized in the presence of standard antioxidants and process stabilizers, namely 2000 ppm of Irganox B 225 (supplied by Ciba Speciality Chemicals, a blend of 50% Irganox 1010, Pentaerythrityl-tetrakis(3-(3′,5′-di-tert. butyl-4-hydroxyphenyl)-propionate, CAS-no. 6683-19-8 and 50% Irgafos 168, Tris(2,4-di-t-butylphenyl)phosphate, CAS-no. 31570-04-4) and 500 ppm of calcium stearate (supplied by Croda Polymer Additives, CAS-no. 1592-23-0). The melt homogenisation was done on a twin screw extruder with the following temperature profile: Zone 1; Zone 2; Zone 3; Zone 4; Zone 5; of 210° C.; 215° C.; 220° C.; 215° C.; 210° C. accordingly. The screw speed was set to 250 rpm and the throughput to 3 kg/h, the polymer melt being extruded through two circular dies into a cooling water bath for solidification and pelletized subsequently.

The polymer was dried in an oven, assisted by a flow of warm nitrogen, and samples were analysed. The results are summarized in Table 2.

TABLE 1 Polymerisation parameters IE1 IE2 IE3 IE4 IE5 Bulk Phase: Temperature 70 70 70 70 70 [° C.] H₂ amount 0.1 0.06-0.1  0.3 0.3 0.3 [bar] Time [min] 70-85 75-85 45-50 70 55-65 Gas Phase: Temperature 80 80 80 80 80 [° C.] H₂ amount 0 0 0 0 0 [bar] C3/C2 by 70/30 80/20 80/20 80/20 80/20 GC [mol/mol] Time [min] 110  90-120 150 180 150-200

The material composition data of the inventive examples IE1, IE2, IE3, IE4 and IE5 and the comparative examples CE1 and CE2 are listed in table 2:

TABLE 2 Analytical characterisation IE1 IE2 IE3 IE4 IE5 CE1 CE2 XCS (resin) [wt %] 32.1 28.7 40.9 26.4 39.6 28.7 31.1 C2 (XCS) [wt %] 22.4 14.7 14.8 14.5 15.1 30.5 30.3 M_(w) (XCS) [kg/mol] 196 200 240 210 230 380 220 M_(w)/M_(n) (XCS) 3.0 3.2 3.0 2.7 3.2 4.7 4.5 IV (XCS) [dl/g] 1.55 1.51 1.43 1.5 1.67 2.34 1.62 T_(m) (XCS) [° C.] 53 53 54 54 52 67 66 XCU (resin) 67.9 71.3 59.1 73.6 60.4 71.3 68.9 C2 (XCU) [wt %] 3.9 2.7 4.2 4.1 2.9 8.3 5.8 IV (XCU) [dl/g] 2.03 2.05 1.92 1.94 1.72 2.66 1.94 M_(w) (XCU) [kg/mol] 259 269 235 242 205 450 310 M_(w)/M_(n) (XCU) 2.5 2.4 2.5 2.4 2.4 5.9 5.4 T_(m) (XCU) [° C.] 148 148 140 139 148 144 145 T_(c) (XCU) [° C.] 112 111 101 107 109 104 104

The properties of the inventive examples and the comparative example are compared in Table 3.

TABLE 3 Properties of inventive examples IE1, IE2, IE3, IE4 and IE5 in comparison to comparative examples CE1 and CE2. IE1 IE2 IE3 IE4 IE5 CE1 CE2 MFR (resin) 2.2 2.4 3.0 4.0 6.0 0.8 7.0 [g/10 min] T_(m) (resin) [° C.] 146.0 145.0 137.1 135.3 145.2 141.0 142.9 T_(c) (resin) [° C.] 110.5 108.5 99.8 99.1 107.1 99.0 105.1 Charpy NIS, +23° C. 95 97 99 108 103 83 59.7 [kJ/m²] Charpy NIS, −20° C. 78 11 106 13 104 5 3.1 [kJ/m²] IFW, Force at 4335 260 3834 500 4470 3103 2998 Maximum, −20° C. [N] IFW, Deflection at 12.6 0.9 12 3.7 12.5 11.4 11.2 Maximum, −20° C. [mm] IFW, −20° C., ductile brittle ductile brittle ductile ductile ductile Type of failure Tensile Modulus 420 380 225 345 290 471 523 [MPa] Elongation at 468 466 580 589 611 458 505 break [%]

TABLE 4 Strain hardening factors (SHF) for selected Hencky strains (ε_(H)) of inventive examples IE3, IE4 and IE5 in comparison to comparative examples. SHF at SHF SD strain SHF SHF SD (relative rate 0.3 1 3 10 average (absolute) in %) IE3 (Raheco1) ε_(H) = 1.5 1.25 1.25 1.23 1.23 1.24 0.01 0.9 ε_(H) = 2.0 1.53 1.61 1.50 1.43 1.52 0.07 4.9 ε_(H) = 2.5 1.93 1.97 1.93 1.76 1.90 0.09 4.9 ε_(H) = 3.0 2.45 2.57 2.39 2.25 2.42 0.13 5.5 IE4 (Raheco4) ε_(H) = 1.5 1.20 1.23 1.19 1.18 1.20 0.02 1.8 ε_(H) = 2.0 1.56 1.49 1.41 1.39 1.46 0.08 5.3 ε_(H) = 2.5 1.81 1.93 1.75 1.63 1.78 0.12 7.0 ε_(H) = 3.0 2.36 2.33 2.10 1.93 2.18 0.20 9.3 IE5 (Raheco2) ε_(H) = 1.5 1.30 1.28 1.24 1.30 1.28 0.03 2.2 ε_(H) = 2.0 1.70 1.62 1.53 1.50 1.59 0.09 5.7 ε_(H) = 2.5 2.10 2.07 1.90 1.86 1.98 0.12 6.1 ε_(H) = 3.0 2.77 2.78 2.48 2.29 2.58 0.24 9.2 CE 1 (ZN) ε_(H) = 1.5 1.02 1.05 0.97 1.06 1.03 0.04 3.9 ε_(H) = 2.0 1.04 1.07 0.88 0.96 0.99 0.09 8.6 ε_(H) = 2.5 1.00 1.06 0.81 0.80 0.92 0.13 14.4 ε_(H) = 3.0 1.00 1.05 0.72 — 0.92 0.18 19.3 CE 2 (ZN) ε_(H) = 1.5 — 1.00 1.01 1.05 1.02 0.03 2.6 ε_(H) = 2.0 — 1.07 1.02 1.06 1.05 0.03 2.5 ε_(H) = 2.5 — 1.13 1.00 1.01 1.05 0.07 6.9 ε_(H) = 3.0 — 1.10 1.00 0.97 1.02 0.07 6.7 SHF at SHF SD strain SSC-Homo (Homo3) SHF SHF SD (relative rate 1 3 5 10 average (absolute) in %) ε_(H) = 1.5 1.14 1.11 1.08 1.10 1.11 0.02 2.3 ε_(H) = 2.0 1.33 1.23 1.17 1.19 1.23 0.07 5.8 ε_(H) = 2.5 1.59 1.44 1.37 1.31 1.43 0.12 8.5 ε_(H) = 3.0 1.96 1.65 1.55 1.44 1.65 0.22 13.6 SHF at SHF SD strain SHF SHF SD (relative rate 0.5 1 3 10 average (absolute) in %) WE100HMS ε_(H) = 1.5 1.52 1.84 1.39 1.20 1.49 0.27 18.1 ε_(H) = 2.0 2.50 3.28 2.11 1.52 2.35 0.74 31.4 ε_(H) = 2.5 3.94 5.78 3.25 2.24 3.80 1.49 39.2 ε_(H) = 3.0 7.07 9.18 5.06 4.20 6.38 2.22 34.8 WB130HMS ε_(H) = 1.5 2.18 2.04 2.19 1.96 2.09 0.11 5.3 ε_(H) = 2.0 4.08 3.99 4.03 3.72 3.96 0.16 4.1 ε_(H) = 2.5 8.54 7.80 6.90 7.01 7.56 0.77 10.1 ε_(H) = 3.0 16.03 14.40 12.62 12.00 13.76 1.82 13.2

As can be seen from table 4, all inventive examples exhibit moderate strain hardening at both high and low strain rates, which indicates the presence of long chain branching (LCB). In contrast, the comparative examples only showed some strain hardening at lower strain rates but not at high strain rates.

The strain hardening factor (SHF) of the inventive examples is further characterised by a relative small standard deviation. This indicates a more homogenous branching which is in contrast to the strain hardening characteristics of high melt strength polypropylene.

The strain hardening factors (SHF) of the high melt strength polypropylene resins WE100HMS and WE130HMS are characterised by a standard deviation of 31.4% and 10.1%, respectively, at a Hencky strain of 2.5 and 34.8% and 13.2%, respectively, at a Hencky strain of 3.0. This significantly higher standard deviation compared to the inventive examples indicates the significantly lower homogenous branching structure of high melt strength polypropylene.

FIGURE CAPTIONS

FIG. 1 shows the strain hardening factor as a function of Hencky strain at four different strain rates for inventive example 3 (IE3).

FIG. 2 shows the strain hardening factor as a function of Hencky strain at four different strain rates for comparative example 3 (CE3).

FIG. 3 shows the strain hardening factor as a function of Hencky strain at four different strain rates for a high melt strength polypropylene (WB130HMS). 

The invention claimed is:
 1. Heterophasic polypropylene resin having a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min, determined according to ISO 1133, comprising a propylene random copolymer matrix phase (A), and an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase, wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) being present in the resin in an amount of 15 to 45 wt % whereby the XCS fraction has an ethylene content of 25 wt % or lower, and a fraction insoluble in p-xylene at 25° C. (XCU fraction), said heterophasic polypropylene resin being characterised by a strain hardening factor (SHF) of 1.7 to 4.0 when measured at a strain rate of 3.0 s⁻¹ and a Hencky strain of 3.0.
 2. Heterophasic polypropylene resin having a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min determined according to ISO 1133, and having a tensile modulus of 450 MPa or lower when measured according to ISO 527-2 on an injection moulded test specimen of type 1A prepared according to ISO 1872-2 at a temperature of 23° C. and an elongation rate of 1 mm/min comprising a propylene random copolymer matrix phase (A), and an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase, wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) being present in the resin in an amount of 15 to 45 wt % whereby the XCS fraction has an ethylene content of 25 wt % or lower and a molecular weight distribution Mw/Mn of 1.0 to 4.0; and a fraction insoluble in p-xylene at 25° C. (XCU fraction).
 3. The heterophasic polypropylene resin according to claim 1, wherein the fraction soluble in p-xylene at 25° C. (XCS fraction) has a molecular weight distribution Mw/Mn of 1.0 to 4.0.
 4. The heterophasic polypropylene resin according to claim 1 having a tensile modulus of 450 MPa or lower when measured according to ISO 527-2 on a compression moulded test specimen of type 1A prepared according to ISO 1872-2 at a temperature of 23° C. and an elongation rate of 1 mm/min.
 5. The heterophasic polypropylene resin according to claim 1, wherein the fraction soluble in p-xylene at 25° C. (XCS fraction) has a weight average molecular weight (M_(w)) of 180 to 250 kg/mol, measured by GPC according to ISO 16014-1 and -4.
 6. The heterophasic polypropylene resin according to claim 1, wherein the fraction insoluble in xylene (XCU fraction) includes a material formed from propylene and at least one comonomer selected from ethylene, and/or C₄ to C₁₂ alpha olefins.
 7. The heterophasic polypropylene resin according to claim 6, wherein the amount of units derived from comonomers selected from ethylene, and/or C₄ to C₁₂ alpha olefins in the fraction insoluble in xylene (XCU fraction) is 1.5 to 5.0 wt.-% with respect to the total weight of the fraction being insoluble in p-xylene (XCU fraction).
 8. The heterophasic polypropylene resin according to claim 1 having a melting temperature (T_(m)) of 133 to 150° C.
 9. The heterophasic polypropylene resin according to claim 1 having a Charpy notched impact strength at 23° C. of at least 90 kJ/m² and/or a Charpy notched impact strength at −20° C. of at least 10 kJ/m², determined according to ISO 179-1/1eA.
 10. The heterophasic polypropylene resin according to claim 1 withstanding a maximum instrumented falling weight force at −20° C. of at least 250 N, determined according to ISO 6603-2.
 11. An article comprising the heterophasic polypropylene resin according to claim
 1. 12. A process for producing a heterophasic polypropylene resin having a MFR (2.16 kg, 230° C.) of at least 1.0 g/10 min, determined according to ISO 1133, comprising a propylene random copolymer matrix phase (A), and an ethylene-propylene copolymer rubber phase (B) dispersed within the matrix phase, wherein the heterophasic polypropylene resin has a fraction soluble in p-xylene at 25° C. (XCS fraction) being present in the resin in an amount of 15 to 45 wt % whereby the XCS fraction has an ethylene content of 25 wt % or lower, and a fraction insoluble in p-xylene at 25° C. (XCU fraction), said heterophasic polypropylene resin being characterised by a strain hardening factor (SHF) of 1.7 to 4.0 when measured at a strain rate of 3.0 s⁻¹ and a Hencky strain of 3.0, by using the same catalyst for the production of the matrix phase and the dispersed phase.
 13. Process according to claim 12, wherein the catalyst is capable of producing a fraction being soluble in p-xylene at 25° C. having a molecular weight distribution Mw/Mn of 1.0 to 4.0.
 14. Process according to claim 12, wherein the catalyst is a single site catalyst of formula of formula (I) (L)_(m)R_(n)MX_(q)  (I) wherein M is a transition metal of group 3 to 10 or the periodic table (IUPAC), or of an actinide or lantanide, each X is independently a monovalent anionic ligand, such as σ-ligand, each L is independently an organic ligand which coordinates to M, R is a bridging group linking two ligands L, m is 2 or 3, n is 0 or 1, q is 1, 2 or 3, m+q is equal to the valency of the metal, and with the proviso that at least two ligands “L” are of different chemical structure.
 15. Process according to claim 12, wherein the heterophasic polypropylene resin is produced in a multistage process involving at least two reactors, whereby one reactor is operated with a C3/C2 weight ratio of from 68/32 to 90/10. 